KNOWN FAULTS · Ford

Ford Fusion 1.4 / 1.6 TDCi common problems.

2002–2012 · Diesel

Sources are not verified in real time and no entry confirms that your car is affected.

2 known faults with sources

Applies if: Weak points of this model from inspections, breakdown statistics and recalls; anything specific to one engine is stated in the sheet.

Spark plugs, Durashift gearbox and steering on the FusionKnown weak points

Engine / equipment: Ford Fusion (petrol and TDCi)
Period mentioned: 2002–2012
Symptoms: Spark-plug problems on petrol cars from 2007; with the Durashift automated gearbox, if the shift motor fails the gearbox stays in the last gear; leaking tail lights and tailgate handle; at the roadworthiness test, steering, tail lights and indicators; on diesels, typical high-mileage wear.
Possible cause described: TÜV, ADAC and reader data. Recalls: the accessory belt on some petrol engines and a rear-axle bolt (about 126 cars built 13 to 23/9/2011).
Check for the garage: Keep to the timing-belt change; test the Durashift; check steering and tail lights.
Cost cited in the source: No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Applies if: Only the 1.6 TDCi.

1.6 TDCi turbo starved of oilInjection / turbo

Engine / equipment: 1.6 TDCi (DV6)
Period mentioned: Approx. 2004–2018
Symptoms: Hissing from the engine, diesel smell in the cabin, very dark oil between changes and, eventually, a failing turbo with smoke and loss of power.
Possible cause described: The injectors’ copper washers stop sealing; the gases form carbon that gets into the oil and blocks the mesh filter in the turbo oil-feed pipe, starving the turbo. The wrong oil and switching off with the turbo very hot make it worse.
Check for the garage: Check the injector washers and the turbo oil-feed filter. If the turbo is replaced, also clean the sump, intercooler and feed pipe, or the new turbo can fail again. Use low-SAPS oil.
Cost cited in the source: Approx. €1,200–2,500 for a turbo replacement with oil-circuit cleaningA rough figure from the original database, not an up-to-date quote.